Battery charger and assembly

ABSTRACT

Battery chargers and combinations. In some aspects and in some constructions, the invention may provide a combination including a battery charger having a housing n a charging circuit, and protective structure separate from and connectable with the battery charger. The protective structure, when connected, extending from the housing beyond a battery connected to the battery charger. In some aspects and in some constructions, the invention may also provide a combination including a first battery charger, a second battery charger and a connecting structure operable to connect the first battery charger and the second battery charger as a unit. In some aspects and in some constructions, the invention may further provide a combination including a battery charger and a handle separate from and connectable with the battery charger. In addition, in some aspects and in some constructions, the invention may provide a battery charger including a housing having a base and an upper portion opposite the base. A height is defined between the base and the upper portion and the base having a width less than or equal to the height.

RELATED APPLICATIONS

This application claims the benefit of prior filed, co-pendingProvisional Patent Application No. 60/468,556, filed May 7, 2003.

FIELD OF THE INVENTION

The present invention relates to batteries and, more particularly, tobattery chargers.

SUMMARY OF THE INVENTION

Some existing battery chargers, such as power tool battery chargers, arecapable of charging only a single battery at a time (i.e., a singlebattery charger). Also, some other existing battery chargers are capableof charging multiple batteries at a time (i.e., a multiple batterycharger). A single battery charger is typically smaller and lessexpensive than a multiple battery charger. However, for applications inwhich multiple batteries need to be charged, a multiple battery chargermay be preferred by an operator.

In some cases, with the purchase of a rechargeable battery or abattery-powered device, such as a cordless power tool, a customerreceives at least one battery and a single battery charger. When thecustomer purchases additional cordless power tools or kits of powertools, each with a battery and a single battery charger, the customerwill continue to accumulate single battery chargers. The customer mayhave an excess of single battery chargers when a multiple batterycharger may be desired.

Accordingly, the invention provides an apparatus that can, in someconstructions and in some aspects, convert two or more single batterychargers into a multiple battery charger. In such aspects and in suchconstructions, the apparatus can support several single battery chargersto form a battery charger capable of charging multiple batteries.

In some aspects and in some constructions, the invention provides acombination generally including a battery charger including a housinghaving an outer surface, a battery being supportable on the outersurface, and a charging circuit supported by the housing andelectrically connectable to a power source and to the battery; and aprotective structure separate from and connectable with the batterycharger, the protective structure, when connected, extending from thehousing beyond the battery.

Also, in some aspects and in some constructions the invention provides acombination generally including a first battery charger including afirst housing and a first charging circuit supported by the firsthousing and electrically connectable to a power source and to a battery;a second battery charger including a second housing and a secondcharging circuit supported by the second housing and electricallyconnectable to a power source and to a battery; and a connectingstructure operable to connect the first battery charger and the secondbattery charger as a unit.

In addition, in some aspects and in some constructions, the inventionprovides a combination generally including a battery charger including ahousing and a charging circuit supported by the housing and electricallyconnectable to a power source and to a battery; and a handle separatefrom and connectable with the housing, the handle, when connected, beingoperable to carry the battery charger.

Further, in some aspects and in some constructions, the inventionprovides a battery charger generally including a housing having a basefor supporting the battery charger on a surface and an upper portionopposite to the base, a height being defined between the base and theupper portion, the base having a width, the width being less than orequal to the height, a battery being supportable by the housing; and acharging circuit supported by the housing and electrically connectableto a power source and to the battery.

In some aspects and in some constructions, the invention provides anassembly for supporting a first battery charger and a second batterycharger. The assembly may generally include a frame formed to supportthe first battery charger and the second battery charger. The frame mayat least partially define a handle. The assembly may also include alocking subassembly connected to the frame and formed to secure at leastone of the first battery charger and the second battery charger to theframe.

Also, in some aspects, the invention provides a battery charging systemgenerally including a first battery charger connectable to a powersource and operable to charge a first battery and a second batterycharger connectable to the power source and operable to charge a secondbattery. The system may also include a frame configured to support thefirst battery charger and the second battery charger. Further, thesystem may include a first locking mechanism connected to the frame andconnectable with the first battery charger. The first locking mechanismis selectively actuated between a locked position, in which the firstbattery is secured to the frame, and an unlocked position. in which thefirst battery is releasable from the frame. Also, the system may includea second locking mechanism connected to the frame and connectable withthe second battery charger. The second locking mechanism is selectivelyactuated between the locked position, in which the second battery issecured to the frame, and the unlocked position, in which the secondbattery is releasable from the frame.

In addition, in some aspects and in some constructions, the inventionprovides an assembly for supporting a first battery charger and a secondbattery charger. The assembly may generally include a heavy-duty framefor supporting the first battery charger and the second battery charger.The frame may include a base defining a first charger position tosupport the first battery charger and a second charger position tosupport the second battery charger. The base extends beyond the firstbattery charger and the second battery charger when the first batterycharger is in the first charger position and when the second batterycharger is in the second charger position. The frame may also include abar connected to the base. The bar extends beyond the first batterycharger and the second battery charger when the first battery charger isin the first charger position and when the second battery charger is inthe second charger position.

The assembly may also include a first locking mechanism connected to theframe and connectable with the first battery charger. The first lockingmechanism is selectively actuated between a locked position, in whichthe first battery charger is secured to the frame, and an unlockedposition, in which the first battery charger is releasable from theframe. Further, the assembly may include a second locking mechanismconnected to the frame and connectable with the second battery charger.The second locking mechanism is selectively actuated between the lockedposition, in which the second battery charger is secured to the frame,and the unlocked position, in which the second battery charger isreleasable from the frame.

Further, in some aspects and in some constructions, the inventionprovides a battery charger and a handle connectable to the batterycharger.

In addition, in some aspects and in some constructions, the inventionprovides an impact resistant, protective battery charger frame that isconnectable to a battery charger.

In some aspects and in some constructions, multiple single batterychargers are connected to the frame to provide a multiple batterycharger.

In some aspects and in some constructions. the first locking mechanismsecures the first battery charger to the frame, and the second lockingmechanism secures the second battery charger to the frame.

In some aspects and in some constructions, the heavy-duty constructionof the frame allows the single battery chargers to withstand impactsafter falling several feet or being impacted by other objects, inaddition to protecting the batteries attached to the single batterychargers from jarring loose as a result of the impact.

Existing single battery chargers and their individual components are notsuited for outdoor use including being exposed to weather (i.e. sun,rain, wind, etc.) and other contaminants (i.e. dirt, sand, gravel, mud,sawdust, etc.). Weather and contaminants can damage the components ofthe single battery chargers and may render the battery chargersinoperable.

In existing single battery chargers, the charging terminals aretypically exposed to the outside environment. Contaminants (such asdirt, sand, mud, sawdust, etc.) may block the charger terminals andprevent electrical connection between the charger terminals and thebattery (and charging circuit) or cause a short circuit of the chargingcircuit. Also, with existing single battery chargers, the charge statusindicators are not easily seen in outdoor sunlight.

Further, existing single battery chargers may employ an inefficientcharging routine when charging batteries. Some battery chargers maintaincharging even after the battery has reached full charge. Such a routineleads to unnecessary heating of the battery, therefore, decreasing thecycle life of the battery. Other battery chargers terminate chargingwhen a pre-set time limit is reached. This routine can also result inoverheating and a decrease in battery cycle life or may result in abattery not being fully charged when the charging routine hasterminated.

Accordingly, in some aspects and in some constructions, the inventionalso provides a single battery charger which substantially alleviatesone or more problems with existing single battery chargers. In someaspects, the battery charger is a single battery charger for chargingpower tool batteries. In other aspects, the battery charger is aheavy-duty battery charger designed to be used outdoors and/or in harshworking conditions.

More particularly in some aspects and in some constructions, theinvention provides a battery charger generally including a housinghaving an outer surface, a battery being supportable on the outersurface, a charging circuit supported by the housing and electricallyconnectable to a power source and to the battery, and protectivestructure connected to and extending from the outer surface of thehousing, the protective structure extending from the outer surfacebeyond the battery.

Also, in some aspects and in some constructions, the invention providesa single battery charger generally including a housing having an outersurface, a battery being supportable on the outer surface, and acharging circuit supported by the housing and electrically connectableto a power source and to the battery.

In addition, in some aspects and in some constructions, the inventionprovides a single battery charger generally including a housing, acharging circuit supported by the housing and electrically connectableto a power source and to a battery, a vent defined by the housing, thevent releasing heated air from the housing and impeding entry ofcontaminants into the housing, the vent causing the heated air to turndownwardly turn through the vent before being released from the housing,and a drain defined by the housing, the drain releasing contaminantsfrom the housing.

Further, in some aspects and in some constructions, the inventionprovides a single battery charger generally including a housing, acharging circuit supported by the housing and electrically connectablewith a power source, and a battery port connected to the housing andoperable to support a battery. The battery port includes a chargerterminal electrically connectable to the charging circuit toelectrically connect the battery to the charging circuit, a chargerterminal support defining an opening, the terminal being supported inthe opening, and a charger terminal cover supported by the battery port,the terminal cover closing the opening when the battery is not supportedby the battery port.

In addition, in some aspects and in some constructions, the inventionprovides a single battery charger generally including a housing, acharging circuit supported by the housing and electrically connectableto a power source and a battery, an LED positioned at least partiallyoutside of the housing and electrically connected to the chargingcircuit, the LED being operable to display a charge status of thebattery, and a translucent cover connected to the housing and at leastpartially enclosing the LED.

Also in some aspects and in some constructions the invention provides asingle battery charger generally including a charging routine having atemperature rate termination technique. This charging routine isdesigned to function with, for example, Nickel-Metal Hydride (NiMH),Nickel-Cadmium (NiCd), Lithium-ion (Li-ion) etc. battery cells andincludes a maintenance routine and boost routine that follows the normalcharge execution.

In some aspects and in some constructions, the contaminant-resistant airvents prevent any liquid or solid contaminants from entering the chargerhousing. Also, a series of drains are incorporated within the charger topurge any contaminant that may enter the housing, and the suspendedcharging circuits are kept out of contact from such contaminants.

In some aspects and in some constructions, the terminal cover preventsany contaminants from contacting the charger terminals when a battery isnot connected with the battery charger. The cover also provides asweeping action to keep clean the interconnection between the chargingterminals and the battery.

In some aspects and in some constructions, the LED charge statusindicators are bright enough to see in the outdoor sunlight and areviewable from a long distance about a wide range of viewing angles.

In some aspects and in some constructions, the temperature ratetermination technique of the charging routine reduces charge time byseveral minutes, reduces heat due to charging, and/or increases thecycle life of the battery.

Independent features and independent advantages of the present inventionwill become apparent to those skilled in the art upon review of thefollowing detailed description, claims and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front perspective view of a battery charger assemblyembodying independent aspects of the present invention.

FIG. 2 is a front view of the assembly of FIG. 1.

FIG. 3 is a rear view of the assembly of FIG. 1.

FIG. 4 is a top view of the assembly of FIG. 1.

FIG. 5 is a bottom view of the assembly of FIG. 1.

FIG. 6 is a left side view of the assembly of FIG. 1.

FIG. 7 is a right side view of the assembly of FIG. 1. illustrating abattery charger having an attached battery.

FIG. 8 a is a front perspective view of a caddy of the assembly of FIG.1, illustrating multiple cleats positioned on the caddy in a firstconfiguration.

FIG. 8 b is a front perspective view of the caddy of the assembly ofFIG. 1, illustrating the cleats positioned on the caddy in a secondconfiguration.

FIG. 9 is a front view of the caddy of FIG. 8 a.

FIG. 10 is a rear view of the caddy of FIG. 8 a.

FIG. 11 is a top view of the caddy of FIG. 8 a.

FIG. 12 is a bottom view of the caddy of FIG. 8 a.

FIG. 13 is a left side view of the caddy of FIG. 8 a.

FIG. 14 a is a right side view of the caddy of FIG. 8 a.

FIG. 14 b is a right side view of the caddy of FIG. 8 b.

FIG. 15 is a top view of the caddy of FIG. 8 a, illustrating an attachedbattery charger.

FIG. 16 is a cross-sectional view of the caddy and attached chargeralong line 16--16 in FIG. 15.

FIG. 17 is a front perspective view of the caddy of FIG. 8 a,illustrating a partially attached charger.

FIG. 18 is a rear perspective view of the caddy and partially attachedcharger of FIG. 17.

FIG. 19 is a top view of the caddy and partially attached charger ofFIG. 17.

FIG. 20 is a cross-sectional view of the caddy and partially attachedcharger along line 20--20 in FIG. 19.

FIG. 21 is a front perspective view of the assembly of FIG. 1,illustrating a charger being removed from the caddy.

FIG. 22 is a front perspective view of a charger of the assembly of FIG.1.

FIG. 23 is a rear perspective view of the charger of FIG. 22.

FIG. 24 is a front view of the charger of FIG. 22.

FIG. 25 is a cross-sectional view of the charger of FIGS. 22 and 24along line 25--25 in FIG. 24, illustrating an attached battery inphantom.

FIG. 26 is a rear view of the charger of FIG. 22

FIG. 27 is a top view of the charger of FIG. 22.

FIG. 28 is a bottom view of the charger of FIG. 22.

FIG. 29 is a left side view of the charger of FIG. 22.

FIG. 30 is a right side view of the charger of FIG. 22.

FIG. 31 is a cross-sectional view of a portion of the caddy along line31--31 in FIG. 11.

FIG. 32 illustrates a battery port as viewed from the inside of thecharger.

FIG. 33 is a cross-sectional view of the port along line 33--33 in FIG.32.

FIG. 34 is a cross-sectional view of the port along line 34--34 in FIG.33, illustrating charging terminals and their respective electricalleads extending away from the terminals.

FIG. 35 is a front perspective view of the port removed from thecharger.

FIG. 36 is an exploded perspective view of the port of FIG. 35.

FIG. 37 is another exploded perspective view of the port of FIG. 35,illustrating electrical leads connected with the port.

FIG. 38 is a rear perspective view of the port of FIG. 35, illustratingmounting hardware and components involved with mounting the port to thecharger housing.

FIG. 39 is a rear perspective view similar to that of FIG. 38 withportions removed and showing the pivoting structure of a terminal cover.

FIG. 40 is a front perspective view of the terminal cover removed fromthe port.

FIG. 41 is a rear perspective view of the terminal cover of FIG. 40.

FIG. 42 is an enlarged view of a portion of the charger shown in FIG.25, with battery removed.

FIG. 43 is a top perspective view of a battery connectable with theport.

FIG. 44 is a flow chart illustrating a software functional descriptionof the acts involved with charge execution.

FIG. 45 is an exploded perspective view of an LED charge statusindicator assembly.

FIG. 46 is a rear view of a mounting board including a charging circuitand showing the LED charge status indicator assembly electricallyconnecting with the charging circuit.

FIG. 47 is a cross-sectional view of the indicator assembly along line47--47 of FIG. 25.

FIG. 48 is a top perspective view of an alternative construction of abattery charger assembly.

FIG. 49 is a bottom perspective view of the battery charger assembly ofFIG. 48.

FIG. 50 is a side view of the battery charger assembly of FIG. 48, shownin a first orientation.

FIG. 51 is a top view of the battery charger assembly of FIG. 48.

FIG. 52 is a rear view of the battery charger assembly of FIG. 48.

FIG. 53 is a front view of the battery charger assembly of FIG. 48.

FIG. 54 is a bottom view of the battery charger assembly of FIG. 48.

FIG. 55 is a side view of the battery charger assembly of FIG. 48, shownin a second orientation.

FIG. 56 is a top perspective view of the battery charger assembly ofFIG. 48, shown with a battery exploded from the battery chargerassembly.

FIG. 57 is a bottom perspective view of the battery charger assembly andthe battery of FIG. 56.

FIG. 58 is a side view of the battery charger assembly and the batteryof FIG. 56, shown in a first orientation.

FIG. 59 is a top view of the battery charger assembly and the battery ofFIG. 56.

FIG. 60 is rear view of the battery charger assembly and the battery ofFIG. 56.

FIG. 61 is a front view of the battery charger assembly and the batteryof FIG. 56.

FIG. 62 is a bottom view of the battery charger assembly and the batteryof FIG. 56.

FIG. 63 is a side view of the battery charger assembly and the batteryof FIG. 56, shown in a second orientation.

FIG. 64 is a top perspective view of the battery charger assembly ofFIG. 48, shown with a battery connected to the charger assembly.

FIG. 65 is a bottom perspective view of the battery charger assembly andthe battery of FIG. 64.

FIG. 66 is a side view of the battery charger assembly and the batteryof FIG. 64, shown in a first orientation.

FIG. 67 is a top view of the battery charger assembly and the battery ofFIG. 64.

FIG. 68 is a rear view of the battery charger assembly and the batteryof FIG. 64.

FIG. 69 is a front view of the battery charger assembly and the batteryof FIG. 64.

FIG. 70 is a bottom view of the battery charger assembly and the batteryof FIG. 64.

FIG. 71 is a side view of the battery charger assembly and the batteryof FIG. 64, shown in a second orientation.

FIG. 72 top perspective view of a pair of battery charger assembliesconnected to one another in the second orientation, shown with a batteryconnected to each battery charger assembly.

FIG. 73 is a bottom perspective view of the pair of battery chargerassemblies and batteries of FIG. 72.

FIG. 74 is a side view of the pair of battery charger assemblies and thebatteries of FIG. 72.

FIG. 75 is a top view of the pair of battery charger assemblies and thebatteries of FIG. 72.

FIG. 76 is a front view of the pair of battery charger assemblies andthe batteries of FIG. 72.

Before at least one embodiment of the invention is explained in detail,it is to be understood that the invention is not limited in itsapplication to the details of the construction and the arrangements ofthe components set forth in the following description or illustrated inthe drawings. The invention is capable of other embodiments and of beingpracticed or carried out in various ways. Also, it is understood thatthe phraseology and terminology used herein is for the purpose ofdescription and should not be regarded as limiting.

DETAILED DESCRIPTION

A battery charger assembly 10 embodying independent aspects of theinvention is illustrated in FIGS. 1-7. Generally, the assembly 10includes at least one and, in the illustrated construction, multiplechargers 14 supported by a frame, or battery charger caddy 18. As shownin FIGS. 1-7, the caddy 18 is configured to support three chargers 14.However, the caddy 18 may alternatively be configured to support anynumber of chargers 14.

As shown more clearly in FIG. 8 a, the caddy 18 includes a base 22designed to buffer and cushion the chargers 14 supported by the base 22.Multiple insets 26 formed in the base 22 define multiple locations inwhich respective chargers 14 may be supported. However, in otherconstructions of the caddy (not shown), the base may be substantiallyflat, such that pre-defined charger support locations are not formed inthe base.

Locking structure or a locking subassembly including multiple,individual locking mechanisms 30 corresponding with each inset 26secures the chargers 14 to the base 22. In the illustrated construction,the base 22 and the locking structure may at least partially provideconnecting structure for connecting one charger 14 to another charger14.

As shown in FIG. 8 a, the locking mechanisms 30 include resilientmembers 34 secured to the base 22. In the illustrated construction, theresilient members 34 are fastened to the base using ordinary fasteners38. However, the resilient members 34 may alternatively be snap-fit withthe base 22, welded to the base 22, adhesively attached to the base 22,or integrally formed with the base 22. Each resilient member 34 includesa hook portion 42 engageable with one portion of the charger 14, and atab portion 46 releasably engageable with another portion of the charger14. The tab portion 46 is movable between a locked position, in whichthe charger 14 is secured to the base 22, and an unlocked position, inwhich the charger 14 is releasable from the base 22.

In the illustrated construction (see FIGS. 16 and 20), the charger 14includes a housing 50 configured with a slot 54 in the front and towardthe bottom of the housing 50. The slot 54 is configured to receive thehook portion 42 of the resilient member 34 to partially secure thecharger 14 to the base 22.

Also, in the illustrated construction (see FIGS. 16 and 20), the housing50 is configured with a projection 58 in the rear and toward the bottomof the housing 50. The tab portion 46 of the resilient member 34includes a locking portion 62 having a similar shape as the projection58 on the housing 50. The charger 14 is completely secured to the base22 when both the hook portion 42 engages the slot 54 in the housing 50and when the locking portion 62 engages the projection 58 of the housing50.

As shown in FIGS. 16 and 20, to attach a charger 14 to a resilientmember 34, the charger 14 is first angularly positioned in the inset 26such that the hook portion 42 of the resilient member 34 is allowed toengage the slot 54 in the front of the housing 50 to partially securethe housing 50 to the base 22 (see FIG. 20). After the hook portion 42is engaged with the slot 54, the charger 14 is pivoted toward the inset26 such that the tab portion 46 is initially deflected by the projection58. The charger 14 is further pivoted until the tab portion 46 isallowed to return to its undeflected shape upon the locking portion 62encountering the projection 58 in the housing 50 (see FIG. 16). Themating contact between the locking portion 62 and the projection 58positively and fully secures the charger 14 to the base 22.

To release the charger 14 from the resilient member 34, the tab portion46 is depressed so that the locking portion 62 is moved away from matingcontact with the projection 58 of the housing 50, therefore allowing thehousing 50 to be pivoted away from the inset 26 to partially release thehousing 50 from the resilient member 34. The housing 50 is then moved sothat the hook portion 42 disengages the slot 54 in the housing 50 tocompletely release the charger 14 from the resilient member 34 and thebase 22. However, in other constructions of the caddy (not shown), theresilient members 34 may be configured in alternate forms, such that thehook and tab portions 42, 46 utilize alternate shapes to engagerespective portions of the housing 50. Further, the locking mechanisms30 may take other forms (rather than the resilient members 34) to securethe chargers 14 to the base 22.

However, in other constructions of the caddy (not shown), the lockingsubassembly may comprise a one-piece design, such that the one-piecelocking subassembly is operable to secure multiple chargers 14 to thebase 22. Also, the locking subassembly may include inter-engagingstructure, such as a projection and a groove defined by the base 22, anda projection and a groove defined by the housing 50, whereby the housing50 may be secured to the base 22 by engaging the groove of the base 22with the projection of the housing 50, and engaging the groove of thehousing 50 with the projection of the base 22. Such a lockingsubassembly may be similar to the inter-engaging structure generallyprovided by a battery and a battery charger, described below, or by thebattery and a power tool.

Further, one of the housing 50 and the base 22 may include a lockingmember movable between a locked position, in which the housing 50 islocked to the base 22, and an unlocked position. Such a lockingsubassembly may be similar to the locking arrangement generally providedbetween a battery and a power tool.

Also, other items and/or components may be supported and/or secured tothe base 22 in locations defined by the insets 26. For example, astorage container may include a housing defining similar structure(i.e., a slot 54 and a projection 58) engageable with the lockingmechanisms 30. Also, other electrical components, for example, audiocomponents, such as a radio, a MP3 payer, a CD player, speaker(s), videocomponents, etc., may be supported and/or secured to the base 22.

With reference to FIGS. 3-4, the base 22 also includes a power strip 66connected thereto in the rear of the base 22. The power strip 66 iselectrically connected to a power source (not shown), such as 110-VACline power, through a main power cord 70 (shown only in FIGS. 3-4).However, the power strip 66 may alternatively be electrically connectedto a DC power source. In the illustrated construction, the power strip66 is configured with three power outlets 74 capable of receiving powerfrom the power source. However, in other constructions of the powerstrip (not shown), the power strip 66 may be configured with any numberof power outlets 74. The power outlets 74 provide a location for thechargers 14 to plug their respective power cords 76 (shown only in FIGS.3-4) so that each charger 14 can receive power from the power source.The power strip 66 may also include a circuit breaker (not shown)therein configured to protect the electrically-connected chargers 14from power surges from the power source. Further, any electricalcomponent configured to receive 110-VAC line power may be electricallyconnected to the outlets 74 to receive power. The power strip 66includes other internal electrical components (not shown) similar tocomponents utilized in conventional power strips. As such, descriptionof those components will not be discussed herein.

In the illustrated construction, the base 22 is blow molded from a highdensity polyethylene (HDPE) which is a very strong and impact-resistantmaterial. This material selection allows the base 22 to more effectivelyabsorb the energy associated with an impact. In the illustratedconstruction, a uniform wall thickness of about 0.100″ around the base22 prevents its collapse (especially near the corners) when the base 22is impacted after a fall or some other impacting event.

Also, in the illustrated construction, the resilient members 34 are madefrom a thin gauge metal. However, in other constructions of the caddy(not shown), the resilient members 34 may alternatively be made fromplastic. Further, plastic resilient members 34 may be integrally formedwith the plastic base 34.

As shown in FIGS. 1-4, 6-11 and 13-14 b, a handle 78 is connected to thebase 22. A lower portion 82 of the handle 78 connects to a front portionof the base 22 (see FIG. 31), while multiple braces 84 connect an upperportion 85 of the handle 78 and a rear portion of the base 22. The lowerportion 82 of the handle 78 is connected to the front portion of thebase 22 using a fastener 86, which also connects a foot 90 to a bottomportion of the base 22. The respective braces 84 are also fastened, atone end, to the upper portion 85 of the handle 78, and at an oppositeend to the base 22. The braces 84 connect to the base 22 using a commonfastener (not shown) as another foot 90 connected to the bottom portionof the base 22. Alternatively, in other constructions of the caddy (notshown), the handle 78 and braces 84 may be integrally formed. Further,in yet other constructions of the caddy (not shown), the handle 78 andbraces 84 may be integrally formed with the base 22.

Also, as shown in FIGS. 1-4, 6-11 and 13-14 b, multiple cleats 94 areconnected to the handle 78 and braces 84. In the illustratedconstruction, the cleats 94 are utilized in three pairs to securethereon the respective three power cords 76 of the three illustratedchargers 14. However, in other constructions of the battery chargerassembly (not shown), more or less than three pairs of cleats 94 may beutilized depending on the number of corresponding attached chargers 14.Also, an additional pair of cleats (not shown) may be connected to thehandle 78 and/or the braces 84 for securing thereon the main power cord70 of the power strip 66. In the illustrated construction, the cleats 94are integrally formed with the handle 78 and braces 84. FIGS. 8 a and 14a illustrate the cleats 94 in a first configuration, while FIGS. 8 b and14 b illustrate the cleats 94 in a second configuration.

An ergonomic grip 98 is centrally positioned on the handle 78 to providea comfortable, sure and steady grip on the handle 78. The grip 98 mayinclude an elastic, non-slip material covering to provide comfort whilethe battery charger caddy 18 is carried. In the illustratedconstruction, the handle 78 is made of two halves connected by the grip98. However, in other constructions (not shown), the handle 78 may bemade of a single component, such as, for example, a bar, having the grip98 overmolded or integrally formed with the handle 78.

The handle 78 allows the user to carry the assembly 10 to and from awork site, with or without chargers 14 connected to the caddy 18, andwith or without batteries 102 connected to the chargers 14. As shown inFIG. 7, the attached chargers 14 (one with an attached battery 102) aregenerally encompassed by a boundary defined by the base 22 and handle78. As a result, the handle 78 also functions as a “roll bar,” orprotective structure. More particularly, the lower portion 82 of thehandle 78 protects the front surfaces of the chargers 14 (and anyattached batteries 102) from being impacted by an object or surfacewider than the distance between the lower portion 82 of the handle 78.Similarly, the lower portion 82 of the handle 78, in combination withthe braces 84, protects the side surfaces of the chargers 14 (and anyattached batteries 102) from being impacted by an object or surfacewider than the distance between the lower portion 82 and the braces 84.The base 22 protects the bottom surfaces of the chargers 14 (and anyattached batteries 102) from being impacted during a fall or otherimpacting event.

While the top surfaces of the chargers 14 are generally unimpeded toallow easy connection and removal of the chargers 14 (and the connectionand removal of batteries 102 relative to the chargers 14), the upperportion 85 may provide some protection to the top surfaces of thechargers 14 (and any attached batteries 102) from being impacted by anobject or surface wider than the distance defined by the upper portion85. In other constructions (not shown), an additional top cover (notshown) may be provided to protect the top surfaces of the chargers 14(and any attached batteries 102).

If the assembly 10 were to fall or be impacted during movement around awork site, a combination of the base 22, handle 78 and braces 84 of thebattery charger caddy 18 would help prevent the chargers 14, and anyattached batteries 102, from jarring loose upon impact because the base22, handle 78, or braces 84 will be impacted first. Therefore, one ormore of the base 22, the handle 78 and the braces 84 protect storedchargers 14 and stored batteries 102 on the chargers 14 and at leastpartially provide protective structure.

In the illustrated construction, the bar-like handle 78 at leastpartially provides protective structure for the assembly 10. In otherconstructions (not shown), the protective structure may include a solidwall (not shown) that may extend from the outer surfaces of the housings50 and surround surfaces of the chargers 14 (and any attached batteries102) to recess the chargers 14 into the wall, while allowing access tothe chargers 14 (and any attached batteries 102).

In yet other constructions (not shown), a cover or multiple covers (notshown) may enclose or partially enclose the chargers 14, with or withoutattached batteries 102, to protect them from impact. The cover ormultiple covers may be removable/retractable manually or with insertionof the charger 14 and/or the battery 102.

The chargers 14 also embody independent aspects of the invention. Insome aspects and in some constructions, the chargers 14 are constructedfor heavy-duty use in a harsh working environment (for electricalequipment) such as outdoor construction sites, machine shops,manufacturing floors, etc. The chargers 14 are operable to support andcharge batteries 102, such as, for example, 12V, 14.4V, 18V, 24V, etc.,or similar power tool or other equipment batteries 102 of variouschemistries (NiCd, NiMH, Li, Li-ion, etc.). Generally, the batteries 102include a top surface 106, a bottom surface 110, a front surface 114 andtwo side surfaces 118 to define a generally rectangular shape (see FIG.43). However, the batteries 102 may define any number of shapes.

As shown in FIGS. 22-23, 25, and 29-30, the housings 50 generally definea substantially upright (i.e., extending more vertical than horizontal,in other words, having a height which is greater than a width and/or adepth) shape such that a battery 102 supported by a charger 14 issupported substantially upright. Also, since the housings 50 aresubstantially upright, multiple housings 50 are allowed to be supportedadjacent each other on the caddy 18. The housing 50 also includesmultiple feet 126 providing stability to the housing 50 when supportinga battery 102. The feet 126 help prevent the charger 14 from tippingwhen supporting a battery 102, which can be heavier than the charger 14itself depending on the size and construction of the battery 102.

As shown in FIG. 25, the charger housing 50 is manufactured of a plasticmaterial as a two-piece design. A first shell 130 is connected to asecond shell 134 to form a cavity 138 therebetween. A tongue and agroove (not shown) are utilized to mate the two shells 130, 134, and ano-ring (not shown) is positioned between the two shells 130, 134 to sealthe interface between the two shells 130, 134. The two shells 130, 134are also molded to define a low spot at the bottom of the housing 50when the shells 130, 134 are mated. A drain 142 is positioned in the lowspot to release any contaminant (i.e. dirt, sand, gravel, sawdust, metalshavings, water, oil, grease, etc.) that may enter the cavity 138.

The base 22 may also include one or more drains (not shown) positionedat respective low spots molded into each inset 26. Further, the drains142 formed in the housings 50, and the one or more drains formed in thebase 22 may be in fluid communication to allow any contaminants in thecavity 138 to be released through the drains. Further, the drains may beoffset from one another so that direct access to the cavity 138 throughthe drains is prohibited.

With continued reference to FIG. 25, a charging circuit 146 is supportedby a suspended and cushioned mounting board 150 housed within the cavity138. The mounting board 150 is made of a flame-retardant material, suchas a VØ-rated plastic. The charging circuit 146 and the mounting board150 are formed as an assembly, and the charging circuit 146 is potted inthe flame retardant material to seal and insulate the components of thecharging circuit 146. The components of the charging circuit 146 aresupported on the mounting board 150 with required spacing, sealing andinsulation to meet UL requirements.

The cushioned mounting configuration of the mounting board 150 protectsthe charging circuit 146 during an impact. Such cushioning may beprovided by any elastically deformable material (not shown), such as,for example, rubber washers, positioned between the board 150 andhousing 50.

This mounting configuration also helps minimize exposure of the chargingcircuit 146 to any contaminant (e.g. dirt, sand, gravel, sawdust, metalshavings, water, oil, grease, etc.) that may enter the cavity 138. Anycontaminant entering the cavity 138 will come to rest along an interiorwall or adjacent walls of the housing 50, depending on the orientationof the housing 50. Therefore, with the charging circuit 146 suspended inthe middle of the housing 50, it is unlikely any contaminants willcontact or come to rest on the charging circuit 146.

The charging circuit 146 is connectable to the power source, such as the110-VAC line power through the charger's power cord 76, or a DC powersource. Charger terminals 154 on a battery port 158 connect the battery102 to the charging circuit 146.

The charging circuit 146 may be similar to the charging circuitdescribed in U.S. Pat. No. 6,222,343, issued Apr. 24, 2001, and U.S.patent application Ser. No. 09/672,620, filed Sep. 29, 2000, now U.S.Pat. No. 6,456,035, issued Sep. 24, 2002, which are hereby incorporatedby reference.

The charging circuit 146 may also be similar to the charging circuitdescribed in co-pending U.S. Provisional Patent Application Ser. No.60/440,692, filed Jan. 17, 2003, which is hereby incorporated byreference.

As shown in FIG. 25, lower and upper air vents 162, 164 are defined inthe first shell. The air vents 162, 164 include ascending and steppedpassageways 166 into the cavity 138. Structure defining each passageway166 includes an outer lip 170, a spacer portion 174, which may have asubstantially flat surface, and an inner lip 178 toward the end of theportion 174. This structure helps to prevent any solid (i.e. dirt, sand,sawdust, metal shavings, etc.) or liquid (i.e. water, oil, grease, etc.)contaminants from entering the cavity 138. The outer lip 170 willdeflect contaminants. To enter the cavity 138, the structure of the airvents 162, 164 requires any contaminant to first penetrate the exteriorof the housing 50, move along the substantially flat surface of theportion 174, and then ascend past the level defined by the inner lip178. This tortuous path prevents unforced entry of any solid or liquidcontaminants into the housing 50. However, if contaminants were to enterthe cavity 138, such contaminants would be released through the drain142.

Generally, during operation of the charger 14, heat is generated by thecharging circuit 146. Through unforced convection, cooling air is drawnthrough the lower air vents 162 into the cavity 138 and flows across theheated charging circuit 146. The cooling air is heated by the chargingcircuit 146, causing the heated air to rise and escape the cavity 138through the upper air vents 164.

In other constructions of the battery charger (not shown), the chargermay utilize electrically operated fans to cool the heated chargingcircuit 146 rather than unforced convection through air vents 162, 164.Also, heat removal elements (not shown) such as, for example, heatsinks, heat pipes, etc. may be incorporated into the battery charger todraw heat from the charging circuit 146.

As shown in FIG. 25, an opening 182 is molded into the first shell 130to accommodate a single battery port 158. As shown in FIG. 35, thebattery port 158 includes a battery mounting portion 186, a terminalassembly 190 and a mounting portion 194. The battery mounting portion186 includes battery port projections 198 to guide the battery 102 asthe battery 102 engages with the port 158. The battery port projections198 engage matching battery grooves 202 (shown in FIG. 43) on thebattery 102 to provide positive alignment with and support on the port158. Similarly, battery projections 206 engage matching battery portgrooves 210 to provide positive alignment with and support on the port158. As shown in FIGS. 32-34, a series of charger terminals 154 (part ofthe terminal assembly 190) are recessed within openings 212 in terminalsupports 214 on the port 158. Electrical leads 218 connect the chargingcircuit 146 with the terminals 154 of the port 158. The mounting portion194 further includes fasteners 222 that connect the port 158 with thehousing 50.

The battery port 158 is connected to the housing 50 in a sturdy mannersuch that if the charger 14 falls with the battery 102 attached, theport 158 will not break off the housing 50. The battery port 158 isdesigned to survive a fall from about at least 4 feet with an attachedbattery 102 without breaking off the housing 50.

At least portions of the charger 14 through which power is transferredare formed of flame-retardant material, such as VØ rated plastic. Theseportions may include the charging circuit 146, the mounting board 150and the battery port 158. As a result, other portions of the housing 50may be formed of other materials.

In the illustrated construction, as explained in U.S. Pat. Nos.6,222,343 and 6,456,035, the battery 102 supplies power to the chargingcircuit 146 to initiate charging. Even with the charger 14 connected toa power source, no power is provided at the terminals 154 if the battery102 is not connected to the terminals 154. Therefore, if the battery 102is not attached to the port 158, there is zero potential between theterminals 154 of the port 158. This helps ensure the charging circuit146 cannot be shorted out when the battery 102 is not attached to theport 158 and reduces the risk of electrical shock when the battery 102is not attached.

As shown in FIGS. 35-39, the battery port 158 also includes a terminalcover 226 that is, in the illustrated construction, spring-biased tocover the terminal supports 214. As shown in FIGS. 40 and 41, theterminal cover 226 includes a hood 230 having a mounting stem 234 oneach side. A ramp 238 is positioned on each stem 234 between the hood230 and a pivot 242, where the cover 226 is attached to the port 158.FIGS. 33 and 38-39 illustrate the cover 226 assembled with the port 158.Biasing members, such as, in the illustrated construction, torsionsprings 246, are positioned between the port 158 and the mounting stems234 to bias the hood 230 to a covered position over the openings 212 inthe terminal supports 214.

In the illustrated construction, the action of sliding the battery 102onto the battery mounting portion 186 causes the terminal cover 226 topivotally retract to uncover the openings 212 in the terminal supports214 and expose the terminals 154 to the battery 102. Specifically, thebattery mounting portion 186 includes an opening 250 through which theramps 238 project. The battery projections 206 engage the ramps 238 uponengaging the battery mounting portion 186. The ramps 238 include a slopesufficient to cause the terminal cover 226 to pivot against the biasingforce of the springs 246, thereby exposing the terminal supports 214 andthe terminals 154 to the battery 102. When the battery 102 is removed,the springs 246 force the cover 226 to pivot back over the terminalsupports 214. The biasing force is sufficient to close the cover 226without preventing attachment of the battery 102.

As shown in FIG. 25, the terminal cover 226 retracts into the cavity 138when actuated by battery insertion. The cover 226 moves along a path tosweep away contaminants and to clear the interconnection between theport 158 and the battery 102. The terminal cover 226 also helps minimizethe exposure of the terminals 154 to the outside environment. Whenclosed, the cover 226 deflects contaminants (i.e. dirt, dust, sand,water, oil, grease, etc.) from adhering to the terminals 154 andadversely affecting the electrical connection between the chargingcircuit 146 and the battery 102.

In alternate constructions (not shown) and in some aspects of theinvention, the terminal cover 226 may move in a different manner, suchas linearly sliding away from the terminal supports 214, rather thanpivoting away from the terminal supports 214 upon the battery 102engaging the ramps 238. Also, the terminal cover 226 may be operable bythe user, such as by depressing a button to retract the terminal cover226.

As shown in FIG. 44, a plurality of charge termination protocols,including a temperature rate (“TR”) termination protocol, and firmwaremodules, including a trickle module 254, a charge module 258 and anequalization module 262, provide control of battery charging.

The TR charge termination protocol monitors the rate of temperatureincrease of a battery 102 during a charging cycle and terminates thecharge flow when the battery 102 reaches a predetermined ratetemperature change. The TR protocol also accounts for thermal laggingwhich causes the battery 102 to continue heating after removal of thecharging current. The TR protocol provides a reduction in battery chargetime, a control of heat increase due to charging, and an increase inbattery life.

The firmware executes code that monitors the normal charge cycle of abattery 102. The charge cycle may be terminated by the TR terminationprotocol as previously described. Termination of the normal charge cycleresults in execution of code pertaining to the trickle module 254. Thetrickle module 254 is operable to set a “trickle” flag in software thatcorresponds to termination of the normal charge cycle and initiation ofthe trickle module 254. Setting the trickle flag initiates the chargemodule 258 and the equalization module 262. The charge module 258 isoperable to impose a maintenance charge on the battery 102 whereby acurrent pulse is applied to the battery 102 for approximately fiveseconds every two minutes.

The equalization module 262 executes code that allows the battery 102 torest and cool for approximately fifteen minutes and sets a time limitfor the equalization to occur. If the equalization module 262 does notexecute within the time limit, the module 262 terminates and the chargemodule 258 continues the maintenance charge. While within the timelimit, a sensor monitors the temperature of the battery 102. If thetemperature is in an acceptable range, a “boost” flag is set insoftware. Setting the boost flag initiates a boost charge cycle, forwhich the maximum duration is set by a boost timer. The boost timer istypically 5 minutes, however, other values are possible depending on thetype and capacity of the battery 102. Either the boost timer or one ofthe charge termination protocols, such as the TR protocol, is operableto terminate the boost charge cycle. If the boost timer expires before acharge a termination protocol executes, the equalization module 262terminates and the charge module 258 continues the maintenance charge.

The equalization module 262 executes once per charging cycle and servesto charge the battery 102 toward 100% of rated charge capacity. The TRtermination protocol controls the charging current level duringexecution of the equalization module 262. The rate of heating istypically lower than seen during the normal battery charge cycle.Supplying a charge flow at a reduced heating rate increases the chargeof the battery 102 toward maximum capacity while minimizing the heatingstress imposed on the battery 102 by the charger 14.

For example, with Nickel metal-Hydride (“NiMH”) batteries, a NiMHbattery is charged at a normal current level (about 3.0 amps) using theTR termination protocol. The expected temperature at the point of chargetermination should be about 40 degrees Celsius, or about 15 degreesabove the ambient air temperature. Due to thermal lagging, the NiMHbattery may continue to heat for between about 15-30 minutes aftercharge termination, where an additional 5-7 degree Celsius rise isusually experienced.

The equalization module 262 includes the following operating steps uponTR charge termination. If the battery 102 is left on the charger 14, thebattery 102 will eventually cool. After cooling, the battery 102 isbetween about 90-95% charge capacity. When the battery 102 has cooledbelow 30 degrees Celsius, the equalization module 262 executes code thatinitiates further charging at a specific charge rate, such as, forexample, a rate that provides a one degree Celsius battery temperatureincrease per minute. Using this routine, the NiMH battery is capable ofaccepting the remaining 5-10% of charge capacity.

As shown in FIGS. 45-47, charge status indicators, includinglight-emitting diodes 266 (“LED”), are electrically connected with thecharging circuit 146 to relay the charging status of the battery 102 tothe user. The LEDs 266 are designed to emit an amount of light necessaryto overcome the intensity of outdoor sunlight. The LEDs 266 arepositioned outside of the housing 50 so that the outer perimeter isgenerally viewable from any direction relative to the housing 50. Forexample, if the charger 14 was positioned on a surface at eye level (inwhich the top side of the charger 14 is not viewable), the outerperimeters of the LEDs 266 are still viewable because the LEDs 266project from the top side of the housing 50. Each LED 266 also includesan LED cover 270 that encloses the portion of the LED 266 that projectsfrom the housing 50. The covers 270, in addition to protecting the LEDs266, also diffuse the light emitted by the LEDs 266 to increase theviewable distance and viewable angle of the LEDs 266. A gasket 274 ispositioned between the cover 270 and the housing 50 to help preventcontamination from entering the housing 50 through the openings in thehousing 50 for the LEDs 266.

In other constructions, the LEDs 266 may be positioned on any viewablesurface of the housing 50, rather than the top surface of the housing50. In other constructions (not shown), other visual indicators such as,for example, a potentiometer-based needle or a liquid crystal displaywindow to provide digital charge status information, may be provided.

In other constructions (not shown) and in some aspects of the invention,the charger may utilize an audio indicator rather than a visualindicator to relay battery charge status to the user. Such audioindicators may include electronic bells, chimes, a pre-recorded voicemessage, etc.

An alternative construction of a battery charger assembly 10A isillustrated in FIGS. 48-71. Reference is made to the above discussionregarding the structure, operation, and alternatives of the batterycharger assembly 10 illustrated in FIGS. 1-21. Common elements areidentified by the same reference numbers “A”.

The assembly 10A has a heavy-duty construction like the assembly 10 andincludes a base 22A having a plurality of feet 90A for supporting theassembly 10A on a support surface, such as, for example a work bench,the ground. and a tool box, in a first orientation (see FIGS. 48 and59). In the illustrated construction, the base 22A includes four feet90A. Alternatively, the base 22A can include any number of feet forsupporting the assembly 10A on a support surface. The base 22A isdesigned to buffer and cushion the battery 102A connected to theassembly 10A. The assembly 10A also includes a handle 78A connected tothe base 22A. The handle 78A includes a first portion 300 projectingoutwardly of the base 22A, a second portion 304 engaging the base 22Aand an ergonomic grip 98A extending to one side of the base 22A.

With continued reference to FIGS. 48-71, the assembly 10A furtherincludes a main power cord (not shown) for providing power to theassembly 10A and a battery port 158A for supporting a battery 102A andelectrically connecting the battery 102A to a charging circuit (notshown) to charge the battery 102A. The assembly 10A also includes acharge status indicator positioned on the base such that the lightemitted from the indicator can be seen from substantially all positionsaround the assembly. The charge status indicator includes a cover 270Aand at least one LED (not shown) and is also positioned within arecessed portion 308 of the base 22A to inhibit impacts on the chargestatus indicator which may damage the indicator or shear-off theindicator. A plurality of lower and upper contaminant-resistant airvents 162A, 164A are defined in the base 22A for allowing air to accessand exit the interior of the base 22A.

With particular reference to FIGS. 64-71, the handle 78A is configuredto project outwardly of the battery 102A when the battery 102A isconnected to the battery port 158A. The handle 78A may provide someprotection to the battery 102A from being impacted by an object orsurface wider than the distance defined between the handle 78A. In otherconstructions (not shown), an additional top cover (not shown) may beprovided to protect the battery 102A.

If the assembly 10A were to fall or be impacted during movement around awork site, a combination of the base 22A and the handle 78A would helpprevent the attached battery 102A from jarring loose or being damagedupon impact because the base 22A and/or the handle 78A will be impactedfirst.

With reference to FIGS. 55, 63 and 71, the assembly 10A is positioned ina second orientation. The assembly 10A can support and charge a battery102A in both the first orientation and the second orientation. The base22A includes a pair of secondary feet 312 and the handle 78A includesfeet portions 316 on each end of the handle 78A. The pair of secondaryfeet 312 and the feet portions 316 are engageable with a support surfaceand together support the assembly in the second orientation. The feetportions 316 and the secondary feet 312 are properly positioned relativeto one another to support the additional weight of a battery 102A andprevent tipping of the assembly 10A when the battery 102A is connectedto the battery port 158A.

The assembly 10A can also be connected to a vertical wall in the secondorientation to support and charge a battery 102A. The feet 90A of thebase 22A are brought into contact with the wall and the assembly 10A canbe connected to the wall in a variety of manners, such as, for examplefasteners, magnets and bonding. Such fasteners, magnets or bonding canbe utilized between the feet 90A and the wall or can be utilized betweensome other location(s) on the assembly 10A and the wall. When theassembly 10A is connected to the wall, the feet portions 316 of thehandle 78A do not engage a support surface, however, the handle 78Astill provides some protection to the battery from being impacted byobjects wider than the handle 78A.

In the illustrated construction, the assembly 10A includes two feetportions 316 on the ends of the handle 78A and two secondary feet 312 onthe base 22A. Alternatively, the assembly 10A can include any number offeet portions 316 and secondary feet 312. In other constructions (notshown), feet portions 316 are provided by a component (not shown) otherthan the handle 78A for engaging a support surface and supporting theassembly 10A on the support surface. In such constructions, thecomponent (not shown) including the feet portions can extend from thebase 22A or the handle 78A and be positioned relative to the secondaryfeet 312 to appropriately support the assembly 10A on the supportsurface both when a battery 102A is connected to the battery port 158Aand when a battery 102A is not connected to the battery port 158A.

It should be understood that any of the components illustrated anddescribed with respect to the assembly 10 illustrated in FIGS. 1-47 andnot shown on the assembly 10A illustrated in FIGS. 48-71 can be utilizedin the assembly 10A. For example, The power outlets 74, the cleats 94and the movable electrical terminal cover 226, among others, are notshown on the assembly 10A, however, may be utilized with the assembly10A.

It should also be understood that the internal components, such as, forexample the charging circuit 146 and the suspended and cushionedmounting board 150, of the assembly 10 that are not illustrated in FIGS.48-71 of the assembly 10A, can be incorporated into the assembly 10A.

It should further be understood that any of the plurality of chargetermination protocols, including a temperature rate (“TR”) terminationprotocol, and any of the firmware modules, including a trickle module254, a charge module 258 and an equalization module 262, discussed abovewith respect to the assembly 10 illustrated in FIGS. 1-47 can beutilized in the assembly 10A illustrated in FIGS. 48-71 to providecontrol of battery charging.

With reference to FIGS. 72-76, a pair of assemblies 10A are positionedin the second orientation and are connected together. When connectedtogether, the feet 90A of the bases 22A engage each other. Theassemblies 10A can be connected together in a variety of manners, suchas, for example fasteners, magnets and bonding. Such fasteners, magnetsand bonding can be positioned between the feet 90A of the bases 22A orcan be positioned between other portions of the assemblies 10A. In thesecond orientation, the secondary feet 312 and the feet portions 316 ofboth assemblies 10A all contact a support surface to provide support tothe connected assemblies 10A and the batteries 102A connected to theassemblies 10A. The positions of the secondary feet 312 and the feetportions 316 of both assemblies 10A are properly positioned to inhibittipping of the assemblies 10 both when the batteries 102A are and arenot connected to the battery ports 158A. The connected assemblies 10Acan be picked-up by grasping either or both hand grips 98A.

Some features and aspects of the chargers 14, the base 22 and the handle78 may also be similar to the battery charger described in U.S. patentapplication Ser. No. 10/289,621, filed on Nov. 7, 2002, which is herebyincorporated by reference.

It should be understood that some aspects of the invention may beincorporated into other types of electrical equipment, such as, forexample, electric power tools, audio components, etc. For example, theheavy-duty construction may be incorporated into audio components andother relatively-less durable electronic equipment for use in harshworking environments. Also, suspended, cushioned and/or sealedelectrical circuits may be incorporated into audio components and suchequipment. In addition, independent features of the invention such as,for example, contaminant-resistant air vents 162, 164, contaminantdrains 142, movable electrical terminal covers 226 and/or protrudingLEDs 266 may be incorporated into electrical equipment such as, forexample, electric power tools, generators, audio equipment,communication equipment, etc.

One or more independent features and independent advantages may be setforth in the following claims:

1. A combination comprising: a battery charger including a housinghaving an outer surface, a battery being supportable on the outersurface, and a charging circuit supported by the housing andelectrically connectable to a power source and to the battery; andprotective structure separate from and connectable with the batterycharger, the protective structure, when connected, extending from thehousing beyond the battery.
 2. The combination as set forth in claim 1,wherein the protective structure includes a base separate from andconnectable to the battery charger for supporting the battery charger ona surface, the base extending from the housing beyond the battery. 3.The combination as set forth in claim 2, wherein the base is blow moldedfrom an impact-resistant plastic material.
 4. The combination as setforth in claim 2, wherein the battery is supported on the outer surfaceof the housing, wherein the battery has a frontal battery surface and alower battery surface, wherein the base is positioned below the lowerbattery surface when the battery is supported on the outer surface ofthe housing and when the base is connected to the battery charger, andwherein the base extends beyond the frontal battery surface.
 5. Thecombination as set forth in claim 2, wherein the protective structureincludes a bar separate from and connectable to the battery charger, thebar, when connected, extending from the housing beyond the battery. 6.The combination as set forth in claim 1, wherein the protectivestructure includes a bar separate from and connectable to the batterycharger, the bar, when connected, extending from the housings beyond thebattery.
 7. The combination as set forth in claim 6, wherein the batteryhas a frontal battery surface and a top battery surface, wherein the barextends beyond the frontal battery surface and the top battery surfacewhen the battery is supported on the outer surface of the housing andwhen the bar is connected to the battery charger.
 8. The combination asset forth in claim 6, wherein the battery has a first side surface, asecond side surface and a top battery surface, wherein the bar includesan upper bar portion, a first lower bar portion, and a second lower barportion, wherein, when the bar is connected to the battery charger, thefirst lower bar portion and the second lower bar portion prevent impactsto the first and second side surfaces of the battery, and the upper barportion prevents impacts to the top battery surface.
 9. The combinationas set forth in claim 6, wherein the bar includes a handle grip forcarrying the battery charger.
 10. The combination as set forth in claim6, and further comprising a base separate from and connectable to thebattery charger for supporting the battery charger on a surface, whereinthe bar is connected to the base.
 11. The combination as set forth inclaim 1 wherein the protective structure is connectable to the outersurface of the housing.
 12. The combination as set forth in claim 1, andfurther comprising locking structure for releasably locking the batterycharger and the protective structure.
 13. The combination as set forthin claim 12, wherein the protective structure includes a base separatefrom and connectable to the battery charger for supporting the batterycharger on a surface, the base extending from the housing beyond thebattery, and wherein the locking structure releasably locks the batterycharger to the base.
 14. The combination as set forth in claim 13,wherein the locking structure includes a recess defined on one of thebattery charger and the base and a projection provided by the other ofthe battery charger and the base, the projection being engageable in therecess to lock the battery charger to the base.
 15. The combination asset forth in claim 14, wherein the projection is movable between alocking position, in which the projection engages the recess to lock thebattery charger to the base, and an unlocking position, in which thebattery charger is removable from the base, and wherein the lockingstructure further includes an actuator operable to move the projectionfrom at least one of the locking position and the unlocking position tothe other of the locking position and the unlocking position.
 16. Thecombination as set forth in claim 14, wherein the locking structurefurther includes a biasing member biasing the projection toward thelocking position.
 17. A combination comprising: a first battery chargerincluding a first housing; and a first charging circuit supported by thefirst housing and electrically connectable to a power source and to abattery; and a second battery charger including a second housing, and asecond charging circuit supported by the second housing and electricallyconnectable to a power source and to a battery; and connecting structureoperable to connect the first battery charger and the second batterycharger as a unit.
 18. The combination as set forth in claim 17, whereinthe connecting structure includes a frame, the first battery charger andthe second battery charger being connectable with the frame as a unit.19. The combination as set forth in claim 18, wherein the frame includesa base, the first battery charger and the second battery charger beingconnectable with the base as a unit, the base supporting the firstbattery charger and the second battery charger on a surface.
 20. Thecombination as set forth in claim 19, wherein the base is blow moldedfrom an impact-resistant plastic material.
 21. The combination as setforth in claim 18, wherein the frame includes a bar.
 22. The combinationas set forth in claim 18, wherein the frame includes a handle forcarrying the combination.
 23. The combination as set forth in claim 18,wherein the connecting structure further includes locking structure forreleasably locking the first battery charger and the second batterycharger with the frame.
 24. The combination as set forth in claim 23,wherein the locking structure includes a recess defined on one of thefirst battery charger and the frame and a projection provided by theother of the first battery charger and the frame, the projection beingengageable in the recess to lock the first battery charger to the frame.25. The combination as set forth in claim 24, wherein the projection ismovable between a locking position, in which the projection engages therecess to lock the first battery charger to the frame, and an unlockingposition, in which the first battery charger is removable from theframe, and wherein the locking structure further includes an actuatoroperable to move the projection from at least one of the lockingposition and the unlocking position to the other of the locking positionand the unlocking position.
 26. The combination as set forth in claim24, wherein the locking structure further includes a biasing memberbiasing the projection toward the locking position.
 27. The combinationas set forth in claim 24, wherein the locking structure includes asecond recess defined on one of the second battery charger and the frameand a second projection provided by the other of the second batterycharger and the frame, the second projection being engageable in thesecond recess to lock the second battery charger to the frame.
 28. Thecombination as set forth in claim 23, wherein the locking structureincludes a first locking assembly operable to releasably lock the firstbattery charger to the frame, and a second locking assembly operable toreleasably lock the second battery charger to the frame.
 29. Thecombination as set forth in claim 17, wherein the connecting structureis at least partially provided by at least one of the first charger andthe second charger.
 30. The combination as set forth in claim 29,wherein the connecting structure includes a recess defined by at leastone of the first battery charger and the second battery charger, and aprojection engageable in the recess to connect the first battery chargerand the second battery charger.
 31. The combination as set forth inclaim 30, wherein the connecting structure includes a first recessdefined by the first battery charger, a first projection engageable inthe first recess, a second recess defined by the second battery charger,and a second projection engageable in the second recess.
 32. Thecombination as set forth in claim 29, and further comprising a handlefor carrying the combination.
 33. The combination as set forth in claim32, wherein the handle is connected to at least one of the first batterycharger and the second battery charger.
 34. The combination as set forthin claim 17, and further comprising protective structure extendingbeyond the batteries connected to the first battery charger and thesecond battery charger.
 35. The combination as set forth in claim 34,wherein the protective structure is separate from and connectable withat least one of the first battery charger and the second batterycharger, the protective structure, when connected, extending from theassociated housing of the at least one of the first battery charger andthe second battery charger beyond the associated battery.
 36. Thecombination as set forth in claim 34, wherein the connecting structureprovides at least a portion of the protective structure.
 37. Acombination comprising: a battery charger including a housing, and acharging circuit supported by the housing and electrically connectableto a power source and to a battery; and a handle separate from andconnectable with the housing, the handle, when connected, being operableto carry the battery charger.
 38. The combination as set forth in claim37, and further comprising protective structure separate from andconnectable with the battery charger, the protective structure, whenconnected, extending from the housing beyond the battery.
 39. Thecombination as set forth in claim 38, wherein the handle provides atleast a portion of the protective structure.
 40. The combination as setforth in claim 37, and further comprising a base separate from andconnectable to the battery charger for supporting the battery charger ona surface.
 41. The combination as set forth in claim 40, wherein thehandle is connectable to the base, and wherein the handle and the basecooperate to carry the battery charger.
 42. The combination as set forthin claim 41, wherein the handle is fixed to the base.
 43. Thecombination as set forth in claim 40, wherein the base is blow moldedfrom an impact-resistant plastic material.
 44. The combination as setforth in claim 37, and further comprising locking structure forreleasably locking the battery charger and the handle.
 45. Thecombination as set forth in claim 44, and further comprising a baseseparate from and connectable to the battery charger for supporting thebattery charger on a surface from wherein the locking structure isoperable to releasably lock the battery charger to the base.
 46. Abattery charger comprising: a housing having a base for supporting thebattery charger on a surface and an upper portion opposite to the base,a height being defined between the base and the upper portion, the basehaving a width, the width being less than or equal to the height, abattery being supportable by the housing; and a charging circuitsupported by the housing and electrically connectable to a power sourceand to the battery.
 47. The battery charger as set forth in claim 46,wherein the width is less than the height.
 48. The battery charger asset forth in claim 47, wherein the width is less than about one-half ofthe height.
 49. The battery charger as set forth in claim 46, whereinthe battery charger is supported on the base in a first orientation, andwherein the housing has a second portion for supporting the batterycharger on a surface in a second orientation.
 50. The battery charger asset forth in claim 46, wherein the housing has a support surface onwhich the battery is supportable and a surface opposite the supportsurface, the width being defined between the support surface and theopposite surface.
 51. The battery charger as set forth in claim 46,wherein the housing has a support surface on which the battery issupportable, the support surface having opposite lateral edges, thewidth being defined between the opposite lateral edges.